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Alternator Plug Melted

544 Views 2 Replies 3 Participants Last post by  neoracer, 
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I have a 83 gl1100a model. The previous owner had it covered in lights front and back. I removed 25+ lights from the bike when I bought it. The wire harness plugbehind the side cover in front of the battery is melted. The stator is still good and it puts out as needed. Some one had previously spliced in a replacement plug and cut back the harness wires a few inches. I have been told to scrap the plug and direct wire the two halves. I will need to add some wire to make the distance. I have checked out the stock wire and found it to have 36 individual strands. The wire I have on hand appears to be the same gauge but only has 26 strands, will this make a difference (increase resistance). Any help appreciated.
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Bagmaster
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Number of strands don't matter. You want to use 12ga. or better. Wire gauges go up in size as the number gets smaller. In affect, 12ga is larger than 14. Make sure it's a good solder connection, not crimp on splices and cover them all up good with heat shrink tubing.
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neoracer
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you can almost bet that if the stator wire connector is melted u probably have the same situation with the connector and or stator wires in that area

replace the dogbone fuse connector with a 30 amp ATO fuse setup also
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